Polymer, polymer microfiber, polymer nanofiber and applications including filter structures

Abstract

Disclosed are improved polymer materials. Also disclosed are fine fiber materials that can be made from the improved polymeric materials in the form of microfiber and nanofiber structures. The microfiber and nanofiber structures can be used in a variety of useful applications including the formation of filter materials.

1. A fine fiber comprising a polymer selected from the group consisting of:
 (a) a blend of a hydrophobic additive and nylon 66, the fine fiber having a fiber size of about 0.01 to 0.5 micron;  
 (b) a blend of a hydrophobic additive and a polymer comprising a blend of at least two different nylon polymers, the fine fiber having a fiber size of about 0.01 to 0.5 micron;  
 (c) a blend of a hydrophobic additive and a nylon polymer comprising a nylon other than a copolymer formed from a cyclic lactam and a C 6-10  diamine monomer or a C 6-10  diacid monomer, the fine fiber having a fiber size of about 0.01 to 0.5 micron; or  
 (d) mixtures thereof; wherein after exposure to air at 140° F. and 100% relative humidity for 1 to 16 hours at least 50% of the fine fiber remains substantially unchanged.  
 
     
     
       2. The fine fiber of  claim 1  wherein the fine fiber comprises a blend of two nylon polymers and has a diameter of 0.01 to 0.2 micron. 
     
     
       3. The fine fiber of  claim 1  wherein the fine fiber survives immersion in hot water at 140° F. and at least 50% of the fiber survives after 5 minutes. 
     
     
       4. The fine fiber of  claim 1  wherein the fiber, when exposed to an air stream having a temperature of about 140° F. and a relative humidity of about 100%, greater than about 50% of the fiber survives for more than 16 hours. 
     
     
       5. The fine fiber of  claim 1  comprising a layer having a thickness of less than about 30 microns. 
     
     
       6. The fine fiber of  claim 1  comprising a layer having a thickness of less than about 20 microns. 
     
     
       7. A fine fiber comprising a polymer selected from the group consisting of:
 (a) an acrylic polymer combined with either a crosslinking agent or a hydrophobic additive, the fiber having a fiber size of about 0.01 to 0.5 micron;  
 (b) a blend of a hydrophobic additive and a polymer comprising a blend of at least two different acrylic polymers, the fine fiber having a fiber size of about 0.01 to 0.5 micron; and  
 (c) mixtures thereof; wherein after exposure to air at 140° F. and 100% relative humidity for 1 to 16 hours at least 50% of the line fiber remain substantially unchanged.  
 
     
     
       8. The fine fiber of  claim 7  wherein the fine fiber can be exposed to an alcoholic solvent at 70° F. and wherein at least 50% of the fiber remains after 5 minutes. 
     
     
       9. The fine fiber of  claim 7  wherein the fine fiber survives immersion in hot water at 140° F. and at least 50% of the fiber survives after 5 minutes. 
     
     
       10. The fine fiber of  claim 7  wherein the fiber, when exposed to an air stream having a temperature of about 140° F. and a relative humidity of about 100%, greater than about 50% of the fiber survives for more than 16 hours. 
     
     
       11. The fine fiber of  claim 7  wherein a temperature of 160° F. is used. 
     
     
       12. The fine fiber of  claim 7  comprising a layer having a thickness of less than about 30 microns. 
     
     
       13. The fine fiber of  claim 7  comprising a layer having a thickness of less than about 20 microns. 
     
     
       14. The fine fiber of  claim 7  wherein the fine fiber comprises a microfiber having a diameter of about 0.1 to 0.5 micron. 
     
     
       15. The fine fiber of  claim 7  wherein the fine fiber comprises a nanofiber having a diameter of about 0.01 to 0.2 micron. 
     
     
       16. A fine fiber comprising the reaction product of a polymer resin and a cross linking agent, the fiber having a fiber size of about 0.01 to 0.5 micron; wherein after exposure to air at 140° F. and 100% relative humidity for 1 to 16 hours at least 50% of the fine fiber remains substantially unchanged. 
     
     
       17. The fine fiber of  claim 16  wherein the fine fiber comprises a blend of two polymer resins and has a diameter of 0.01 to 0.2 micron. 
     
     
       18. The fine fiber of  claim 16  wherein the fine fiber, when exposed to an air stream having a temperature of about 140° F. and a relative humidity of about 100%, greater than about 50% of the fiber survives for more than 16 hours. 
     
     
       19. The fine fiber of  claim 16  wherein the crosslinking agent comprises urea formaldehyde, melamine formaldehyde, phenol formaldehyde, or mixtures thereof. 
     
     
       20. The fine fiber of  claim 16  wherein the crosslinking agent comprises a dialdehyde, trialdehyde, tetraaldehyde, a diacid, a urethane reactant, epoxy reactant, or mixtures thereof. 
     
     
       21. The fine fiber of  claim 16  comprising a layer having a thickness of less than about 30 microns. 
     
     
       22. The fine fiber of  claim 16  comprising a layer having a thickness of less than about 20 microns. 
     
     
       23. A fine fiber comprising an electrospun fiber comprising the reaction product of a polymer resin and a crosslinking agent; wherein alter exposure to air at 140° F. and 100% relative humidity for 1 to 16 hours at least 50% of the fine fiber remains substantially unchanged. 
     
     
       24. The fiber of  claim 23  wherein the fine fiber comprises a blend of two polymer resins and has a diameter of 0.01 to 0.5 micron. 
     
     
       25. The fiber of  claim 23  wherein the fine fiber has a diameter of 0.01 to 0.2 micron. 
     
     
       26. The fiber of  claim 23  wherein the fine fiber, when exposed to an air stream having a temperature of about 140° F. and a relative humidity of about 100%, greater than about 50% of the fiber survives for more than 16 hours. 
     
     
       27. The fiber of  claim 23  wherein the crosslinking agent comprises urea formaldehyde, melamine formaldehyde, phenol formaldehyde, or mixtures thereof. 
     
     
       28. The fiber of  claim 23  wherein the crosslinking agent comprises a dialdahyde, trialdehyde, tetraaldehyde, a diacid, a urethane reactant, epoxy reactant, or mixtures thereof. 
     
     
       29. The fine fiber of  claim 23  comprising a layer having a thickness of less than about 30 microns. 
     
     
       30. The fine fiber of  claim 23  comprising a layer having a thickness of less than about 20 microns.